Forging apparatus



' June 12, 1945. c, A, BRA C LE 2,378,060

FORGING APPARATUS Filed April 28, 1943 5 Sheets-Sheet l 45 fl/zarlas fl. Braac/zler June 12,1945.

Filed April 28, 1943 5 Sheets-Sheet 2 I; I i 61 Z -1 46 E i i L wiasflflzwdllw June 12, 1945. c. A. EQRAUCHLER 2,378,060

FORGING' APPARATUS Filed April 28, .1943 I 5 Sheets-Sheet 3 Charles flflmac/zkr June 12, 1945. c. A. BRAUCHLER FORGING APPARATUS Filed April 28, 1943 5 Sheets-Sheet 4 Patented June 12, 194

UNITED STATES PATENT OFFIC'EB .zsrspso m r rename APPARATUS... v

Charles A. Brauchler, canton, Ohio Application April 28, 1943, Serial N0.4s4',s23-

10 Claims.

The invention relates to forging apparatus and more particularly to .an apparatus for press forging a cylinder head, or the like, toform a recess or cavity therein. I

The invention is especially concerned with the production of cylinder headsfor aircraft engines and the improved.forg-ingapparatusis illustrated and described as designed for producing such cylinder heads.

, It has been ,generalpractice to castthesecylinder heads from aluminum alloys, ;.such as duralumin, but owingto the rapid strides made .in aircraft during the present war, the power output of aircraftengines is increasing to -such extent that cast, heads will not have suflicient strength to withstand much greater. pressures than now generated in the cylinders.

Reluctant to increasethe weight of the engines by making a more massive, cast cylinder head, aircraft engineers experimented with forged cylinder heads to replace the conventional cast head and it was found that a forged-head would have many advantages over the cast cylinder head.

The increased tensile strength of the forged material, over that: of cast materiaLresu'lted ina cylinder head of twice the strength with no in-- crease in weight or size,: an'd'permitted increased power output,, decreased fuel consumption and increased cooling effect.

Owing tothe great number of hammer forging. operations required toproduce a cylinder head forging, the limited number of dropha-mmers in this country of sufiicient size and weight ratus comprising cylinder. operated dies conforming to the outside contour of the forged head,

, and a cylinder operated plunger cooperating for the purpose, the heavy demand. upon drop hammers to produce-these forged cylinder heads in any considerable numbers could not be obtained for about two years, it wasimpossible to produced forged cylinder heads in this manner.

Applicant overcame thisobstacle by developing a method of press forging the forged cylinder heads in two or three operations, as compared with the minimum of nine hammer operations, obtaining the advantages of the forgedfhead without the use of drop hammers and with only a fraction of the time and labor required for drop forging. j

Said method of press forging the cylinder heads forms the. subjectmatter of a copending application for patent filed byapplicant, and the present invention is concerned with the appara- I tus by means of which the final press forging operation of said method is accomplished.

The present invention contemplatessan appatherewith for forming the combustion chamber recess in the head.

The, invention further contemplates the provision" of. such an, apparatus .inwhich the head ispress forged to finished shape in saidcylinder operateddies and-held. therein while the plunger is operated. to form. the-combustion chamber recess and extrude a skirt uponthecylinderhead forging. A I. y

The object of the invention is to provide an apparatus comprising .a fixed die and. a cooperating' movable die, shaped .to conform to the outer contour of thecylinder head. forging, ahydraulic cylinderfor moving the, movable die, and a plunger operated by a hydraulic cylinder located at a right angle. to the die operating cylinder, for forming. the combustion chamber recess in the cylinder head forging while the forging. is held clamped under extreme pressure between said,

improved apparatus in the. manner" illustrated in the accompanying drawings, in which- Figure 11s a vertical,-long-itudina1 sectional view through the improved press forging: appa= ratus, showing the'parts in the operated position with the, dies inclose'd position. and the plunger extendedinto the dies; 1

Fig. 2, a fragmentary sectional view of a por-' ,tion of the die operating cylinder and-piston,

showing the oil connection for rais'ingthe piston; 1

Fig. 3, .a' front elevation of the apparatus; 7 Fig. 4, a top-plan view or the apparatus with parts broken in sectionto show the oil connec tion for withdrawing the plunger operating piston;

Fig.3 5; a section takenon the line -5'5, 1; Fig.6, an enlarged vertical, longitudinal sec-' iional View through the dies, showing a cylinder head forging held therein and the plunger in operated position to formfthe combustion chamber recess in the head and to extrude the skirt therefrom;

Fig. '7, a perspective view ofthe partly completed forging; and i Similar numerals refer to similar parts throughout the drawings.

In order to have a clear understanding of the purpose of the apparatus forming the subject matter of the present invention, the press forging method in which said apparatus is used will be briefly described.

A blank, in the form of a block or ingot of duralumin, or the like, of suitable size is first heated to forging temperature and then press forged in dies shaped to produce the partly completed forging indicated generally at I in Fig. '7 having the rocker boxes II formed thereon.

This partly completed product, at forging temperature, may then be placed in a second set of dies and press forged to the desired finished outer contour as indicated generally at I2 in Fig. 8, and this forging, at forging temperature, may

be placed in an apparatus forming the subject matter of the present application and held in the dies thereof while the plunger of the apparatus is operated to form the combustion chamber recess and extrude a skirt upon the forged head.

Or, if desired, the partly completed product Ill, shown in Fig. '7, heated to forging temperature, may be placed directly in the dies of the apparatus and press forged to finished shape therein and held by the dies while the plunger is operated to form the combustion chamber recess and extrude the skirt.

The improved apparatus includes a pair of hydraulic cylinders comprising the upright cylinder indicated generally at I3 and the horizontal cylinder indicated generally at I4, for operating the dies and plunger respectively, and will be later described. A ring I5, shouldered as at I6 is fitted within the open lower end of thecylinder I3, the shouldered portion of the ring being provided with an annular rib I! received within the correspondingly shaped groove I8 in the lower end of the cylinder.

Screws I9 detachably connect the ring I to the cylinder I3. The piston or ram is slidably mounted with the cylinder I3 and provided at its upper end with the annular shoulder or flange 2I, slidably contacting the inner wall 22 of the cylinder, the remaining portion of the piston being reduced in diameter as at 23 and slidably engaging the inner surface of the ring I5.

For the purpose of preventing leakage of oil around the piston a stuffing box recess 24 is formed in the inner surface of the ring I5 to receive the packing 25 which is held in place as by the gland 26 attached to the ring I5 by the screws 21.

Fluid under pressure may be admitted to the upper end of the cylinder, as by the pipe 28, for driving the piston or ram downward and one or more fluid pipes 29 may extend. through the ring I5 to admit fluid pressure against the underside of the shoulder 2I to drive the piston upward.

The horizontal cylinder I4 has a ring 30 mounted in its open end said ring being shouldered as at 3I and connected to the end of the cylinder as by screws 32. The ring 30 has an elongated, cylindric portion 30a surrounding the reduced portion 33 0f the piston 34 and recessed as at 35 to provide a stufiing box within which is located packing material 36 held in place by the gland 31 which is connected to the end of the cylindric portion 32 of the ring as by screws 38.

The piston 34 is provided with the enlarged annular shoulder or flange 39 slidably fitting,

- apparatus.

within the inner wall 48 of the cylinder and overhanging the ring 30 as best shown in Figure 1.

The cylinder I4 is mounted upon the base plate 4| and is provided with the outturned flange 42 engaging the shoulder 43 at the rear end of the base plate M. A block 44 is mounted upon the forward end portion of the base plate M and the lower or fixed die 45 is mounted upon said block.

The upright front late 46 is provided with the dovetailed lower end 41 mounted in the dovetailed groove 48 formed in the base plate ll and a wedge 49 may be provided for tightly holding the two plates together.

An upper plate 50, similar to the base plate M is provided at its rear end with a shoulder 5I engaging the annular flange 42 upon the cylinder I4 and is provided at its forward end with a dovetailed groove 52 which receives the dovetailed upper end: portion 53 of the front plate 43, a wedge 54 being provided for holding said plates tightly together.

The upper cylinder I3 is connected to the apparatus by means of the upright side plates 55 having the angular shoulders 56 at their lower ends engaging beneath the corresponding shoulders 57 at the sides of the base plate 4| and provided with the dovetailed grooves 53 near their upper ends receiving the dovetailed flanges 59 upon the cylinder I3, wedges 50 being provided for tightly securing these parts together.

Blocks 6| may be provided between the ring I5 and the top plate 50 to properly space the cylinder I3 relative to the other parts of the With this construction all of the parts are rigidly and securely locked together so as to resist the pressures developed in the cylinders which may vary from 1400 to 1700 tons in each cylinder.

The movable die 62, complementary to the fixed die 45, is carried by the piston 23, being connected to the lower end thereof as by the dovetailed rib 63 upon the die and the corresponding groove I54 in the piston, a Wedge 65 being preferably provided for tightly securing the die upon the piston.

The plunger 66 is mounted upon the end of the piston 34 and cooperates with the dies 45 and 62 as will be later described. The front plate 46 is provided in its upper portion with an opening 61 through which the forging may be passed toplace it in or remove it from the lower fixed die 45.

Oil under pressure may be admitted to the outer end of the cylinder I4, as by the pipe 68, and one or more oil pipes 69 may be located through the ring 30 for admitting oil under pressure to the opposite end of the cylinder for withdrawing the piston 34.

The fixed die 45 and movable die 62 have cavities I0 and II respectively formed therein conforming to the finished outer contour of the forging I2 as shown in Fig. 8 and also shaped to form the extruded neck I2 at the lower end of the forging as shown in Fig. 6. The plunger 66 has a rounded nose I3 shaped to form the combustion chamber recess I4 in the heated forging as shown in Fig. 6.

In operating the apparatus the forging I2, as shown in Fig. 8, may be heated to forging temperature and passed through the opening 61 and placed in the cavity Ill of the fixed lower die 45, the piston 23' then being moved downward so as to clamp the heated forging tightly bemay be passed to the dies.

aerate confornito the contour-of -the forgingd2: The piston 33 I is their operated" forcing .the'

rounded nose'13 of the'plunge1 6B into-the heated forging, forming the. combustion-" chamber recess 1 4 therein, the metal extruded by this :operation forming theskirtns' i In this =operation the onlyufunctiorr of the dies 45 and: 62 is=to hold thewheated forgingirigidly in place while the plunger is :operated toproduce the combustion chamberrecessand'the skirt, a

However, the manufactureof :these press forged cylinder heads may be expedited by eliminating one step in -the. method,x';the1 partlyilcompleted forging l0, .5 shown: in 1Fig.g;v'l, be'ingbheated to forging temperature and'plaoeds in the-lower fixed die" 45,- the ,upper movable die ,62 .being ,then

lowered, pressi'forging the heated-metahto, the

. means connecting the \,movable die to said piston,

a' second fluidoperated cylinder locatedat an angle torthefirst mentioned -cylinder a piston in the second cylinder ,and a. plunger on the second pistoncooperating with ;the dies, a base plate and a-qtop plate- .connected. .at-.theirrear ends to: the second acylinder,-;a',-front plate con: nected:to:the::forward .ends off-the plates,an d side plates connected at opposite-endsto the: first cylinder .andto the base plate. I

' 2. Apparatusincluding a flxed flea-movable;

die, said dies having complementary cavities a cylinder, a fluid operatedpiston in said cylinder,

means connecting the movable die to said piston,

a second fluid io'peratedycylinder located at an angle to the first mentioned cylinder, a piston in the second cylinder and a plunger on the second piston cooperating with the dies, 2. base plate and a top plate connected at their rear ends to the second cylinder, a front plate connected to the forward ends of the plates, and side plates connected at opposite-ends to the first cylinder and to the base plate, there being an opening r in the top plate through which the first piston is located and blocks clamped between the first cylinder and the top plate.

3. Apparatus including a fixed die, a movable die, said dies having complementary cavities, a L

cylinder, a fluid operated piston in said cylinder, means connecting the movable die to said piston, a second fluid operated cylinder located at an angle to the first mentioned cylinder, a piston in the second cylinder and a plunger on the second piston cooperating with the dies, a base plate and a top plate connected at their rear ends to the second cylinder, a front plate connected to the forward ends of the plates, and side plates connected at opposite ends to the first cylinder and to the base plate, there being an opening in the front plate through which work 'platesand on the first cylinder;

end-piston cooperatingwithithe dies, 2;. basepl'ate and a top plate lconnectd-at ,theirrean ends to the second cylinder; alfrontzplate. connected. to the forward endszof the plateavand 'sideplates connected at opposite ends to-thekfirstrcylinder. and to the base -plate, ther e;=being an:.opening! in the top plate. throughcwhich; the; .first :piston is located blocks clamped. between ithel firstcylinder Randi the top, plate, .andltherebeing; an. open ing 'in the front. plate through which work. may bepassed tothe dies..

5; Apparatusinclu'ding a fixed die; anmovable die;;r said dies I having complementary cavities, a cylinder, afiuid operated piston saidcylinder, means 1 connecting themovable die :to said piston, a secondlfluid operated-.cylinder located at an angleto the first mentioned cylinder, a piston in the second cylinder, a plunger on the second 1315-: 1'

ton oooperatingzwith. the dies,.;a base plate-on which the fixed die is mounted; interlockingzfore mations on i the rear portion of the base plate and on the second Ecylinder, a front plate, interlocking formations upon-the: lower portion .of the front plate-and the forward portion-0f thebase'plate, a top plate, interlocking formations onqtlierear portion of'thetopplate andion the second'-cylin-. der interlocking formations on the: .upperilpor-r tion..ofithefront plate andon the forwardiportion of the top plate, side plates; mterlockin formations on the .lower p'orti'ons:ofwthe side plates and on the base; plate and interlocking formations on the vupper portionsof the side 6.:Apparatus including a fixed die; a: movable die, said dies having complementary-1'c'avitieaxa cylinder, a fluid operated piston in said cylinder',; means connecting themovable die to said piston, ausecond fluid operated cylind'erl'ocatedat an angle toathe' first mentioned cylinder ia piston in thesecond cylinder, a plungeron the second piston cooperating with :the dies,.-a baseiplate I onwhich 'the fixed-die is imounted interlocking formations on the rear portion of the base plate and on the second cylinder, a front plate having an opening through which work may be passed to the dies, interlocking formations upon the lower portion of the front plate and the forward portion of the base plate, a top plate, interlocking formations on the rear portion of the top plate and 1011 the second cylinder, interlocking formations on the upper portion of the front plate and on the forward portion of the top plate, side plates, interlocking formations on the lower pori a second fluid operated cylinder locatedat an 4. Apparatus including a fixed die, a movable die, said dies having complementary cavities, a

cylinder, a fluid operated piston in said cylinder,

angle to the first mentioned cylinder, a piston in the second cylinder and a plunger on the secangle to the first mentioned'cylinder, a piston in the second cylinder, a plunger on the second piston cooperating with the dies, a base plate on which the fixed die is mounted, interlocking formations on the rear portion of the base plate and on the second cylinder, a front plate, interlock.-

ing formations upon the lower portion of the front plate and the forward portion of the base plate, a top plate, interlocking formations on the rear portion of the top plate and on the second cylinder, interlocking formations on the upper portion of the front plate and on the forward por-' tion of the top plate, side plates, interlocking formations on the lower portions of the side plates and on the base plate and interlocking formations on the upper portionsof the side plates and on the first cylinder, there being an opening in the top plate through which the first piston is located. and blocks clamped between the first cylinder and the top plate.

8. Apparatusincluding a fixed die, a movable die, said dies havingcomplementary cavities, a

cylinder, dovetailed flanges on said cylinder, a-

fluid operated pistonin said cylinder, means connecting the movable die to said piston, a. second fluid operated cylinder located atan angle to the first mentionedcylinder, an outturned flange on the second cylinder, a piston in the second cylinder, a plunger on the second piston cooperating with the dies, a base plate on which the fixed die is mounted, a shoulder on the rear portion of the base plate interlocking with the flange on the second cylinder, a front plate having dovetailed upper and lower ends, there being a dovetailed groove in the front portion of the base plate receiving the dovetailed lower end of the front plate, a top plate having a shoulder interlocking with the flange upon the second cylinder and a dovetailed groove receiving the dovetailed upper end of the front plate, side plates having dovetailed grooves in their upper ends receiving the dovetailed flanges onthe front cylinderand interlocking shoulders on the lower ends of the side plates and on the sides of the base plate.

9. Apparatus including a fixed die, a movable die, said dies having complementary cavities, a cylinder, dovetailed flanges on said cylinder, a fluid operated piston in said cylinder, means connecting the movable die to said piston, a second fluid operated cylinder located at an angle to the first mentioned cylinder, an outturned flange on the second cylinder, a piston in the second cylinder, a plunger on the second piston cooperating with the dies, a base plate on which the fixed die is mounted, a shoulder on the rear portion of the base plate interlocking with the flange on the second cylinder, a front plate having an opening through which work may be passed to the dies and having dovetailed upper and lower ends, there being a dovetailed grodve in the front portion ofv the base plate receiving the dovetailed lower end of the front plate, a top plate having a shoulder interlocking with the flange upon the second cylinder and a dovetailed groove receiving the dovetailed upper end of the front plate, side platesihaving dovetailedgrooves in their upper ends receiving the dovetailed flanges on the front cylinder and interlocking shoulders on the lower ends of the side plates and on the sides of the base plate. t

10. Apparatus including a fixed die, a movable die, said dies having complementary cavities, a

cylinder, dovetailed flanges on said cylinder, a fluid operated piston in said cylinder, means connecting the movable die to said piston, a second fluid operated cylinder located at an angle to the first mentioned cylinder, an outturned flange on the second cylinder, a piston in the second. cylinder, a plunger on the second piston cooperating with the dies, a base plate on which the fixed die is mounted, a shoulder on the rear portion of the base plate interlocking with the flange on the second cylinder, a front plate having dovetailed upper and lower ends, there being a dovetailed groove in the front portion of the base plate receiving the dovetailed lower end of the front plate, a top plate having a shoulder interlocking with the flange upon the second cylinder and a dovetailed roove receiving the dovetailed upper end of the front plate, side plates having dovetailed grooves in their upper ends receiving the dovetailed flanges on the front cylinder and interlocking shoulders on, the lower ends of the side plates and on the sides of the base plate, there being an opening in the top plate through which the first piston is located and blocks clamped between the first cylinder and the top plate.

CHARLES A. BRAUCHLER. 

